Battery plate feeder having low vacuum, high flow rate pick-up head

ABSTRACT

A pickup mechanism for removing porous battery plates from a stack of battery plates includes a pickup head for removing a top plate from the stack of battery plates. An opening in the pickup head has an area that is at least 50% of the surface area of the plate. The air flow through the opening in the pickup head is at least 200 CFM and the vacuum at the pickup head is less than 7 inches of water.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent application Ser. No. 10/282,993, filed Oct. 28, 2002, the entirety of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

The subject invention relates to a feeder which lifts porous battery plates sequentially off of a stack of plates and transports them serially for further processing, and in particular to such a feeder with a pick-up head having a low vacuum and high airflow.

In modern storage batteries, the lead battery plates are encapsulated in a microporous material. The encapsulation process is automated and requires that plates be fed to an encapsulation machine serially. Plate feeders are used to lift individual plates off of a stack of plates and feed them to the encapsulation machine. These plate feeders use a pick-up head which is connected to a vacuum source to lift the plates off of the stack. However, because battery plates are porous, and the porosity varies from plate to plate, if the pickup head is brought into contact with the top plate to pick it up, multiple plates will be picked up. As a result, the pickup head is only brought close to the plates being picked up and the vacuum pulls the top plate away from the stack of plates and up to the pickup head. Historically this has been accomplished by using a pickup head with an opening having an area which is very small relative to the surface area of the plates being picked up and a relatively high vacuum, in the order of several inches of mercury. This small opening results in a relatively low airflow into the pickup head.

In recent years, battery plates have become thinner, and thus far more porous. As a result, it has become more likely that this high vacuum will pass through the top plate and pull the next plate off of the stack also. If the vacuum is reduced, there will be less multiple plate pickups but there will be more cases where no plates are picked up. This problem occurs most often with plates at the highest end of the range of porosity, because these plates are the most difficult to pick up and at the same time are the most likely to have a second plate picked up with them.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a pickup mechanism for removing porous battery plates from a stack of battery plates generally comprises a pickup head for removing a top plate from the stack of battery plate. The pickup head has a pickup face with an opening having a predetermined area defined therein. A vacuum source connected to the pickup head is adapted to pull the top plate against the pick-up head such that a surface area of the plate contacts the pick-up head. The vacuum source and the predetermined opening are sized such that a vacuum of less than 7 inches of water and an air flow of more than 200 CFM is created at the opening.

In another aspect of the present invention, a pickup mechanism for removing porous battery plates from a stack of battery plates generally comprises a pickup head for removing a top plate from the stack of battery plate. The pickup head has a pickup face with an opening having a predetermined area defined therein. A vacuum source connected to the pickup head is adapted to pull the top plate against the pick-up head such that a surface area of the plate contacts the pick-up head. The predetermined surface area is at least 50% of the surface area of the top plate.

In another aspect of the present invention, a method for removing a porous battery plate from a stack of battery plate generally comprises providing a stack of battery plates. A pickup head has a pickup face with an opening having a predetermined opening area. A vacuum of less than 7 inches of water and an air flow of more than 200 CFM is created at the opening. The pickup head is moved toward the stack of battery plate to where a top plate in the stack is pulled away from the stack and up against its pick-up face.

Other objects and features will be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of a plate feeder embodying the subject invention.

FIG. 2 is a side elevation of the plate feeder of FIG. 1, partially broken away to show hidden detail, with the feed head at its lowest position where it is picking up a plate.

FIG. 3 is a plan view of a plate being picked up, taken along the line 3-3 of FIG. 2.

FIG. 4 is a side elevational view, partially broken away to show hidden detail, of the plate feeder of FIG. 1 with the feed head in its fully raised, discharged position.

FIG. 5 is fragmentary side elevational view of a plate feeder that is another embodiment of the invention.

FIG. 6 is a fragmentary plan view of the plate feeder shown in FIG. 5.

FIG. 7 is a sectional view taken along the line 7-7 of FIG. 5.

FIG. 8 is a sectional view taken along the line 8-8 of FIG. 6.

FIG. 9 is a sectional view, similar to FIG. 8, showing the transport mechanism of the invention in a different location.

FIG. 10 is a plan view of a battery plate attached to the pickup head of the embodiment of the invention shown in FIG. 5.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1-4 of the drawings, a plate feed apparatus 11 has a platform 10 which carries a stack of battery plates 12. The plates would normally be oriented horizontally on top of each other, as shown, but they could have other orientations as well. The platform 10 moves vertically and a vertical stack indexing mechanism, shown schematically as 14, raises the stack by an incremental amount each time a plate is removed from the top of the stack. Mechanisms of this type are well known in the feeder art. A mechanism, shown schematically at 16, is also provided to place a new stack of plates on the platform when all of the plates have been removed from the current stack. Mechanisms of this type are well known in the feeder arts also.

Located above the platform 10 is a pickup head 18. The pickup head has a pickup surface 20 with a pickup opening 22 located in it, FIG. 3. While battery plates have varying and unequal thicknesses, the pickup surface is generally parallel with and located over the stack of plates 12. The pickup head is connected to a vacuum source 24 through a vacuum tube 26. The vacuum source 24 draws air into the pickup opening 22 and creates a vacuum at the pickup opening. A pickup mechanism, shown schematically at 28, causes the pickup head to be raised and lowered and moved from side to side, as will be explained more fully later. Mechanisms of this type are well known in the feeder arts also.

Referring now in particular to FIG. 3, in order to prevent two plates from being picked up at the same time, the opening 22 in the pickup head is much larger relative to the plate 12 being picked up than has heretofore been provided. The area of the opening 22 is at least 50% of the surface area of the plate 12. This allows the air flow into the pickup head to be much larger than what occurs in prior art pick-up heads and the vacuum to be much lower. The flow into the pickup head is at least 200 CFM and preferably falls within the range of 200-800 CFM. The vacuum is less than 7 inches of water and preferably is within the range of 2-7 inches of water. Testing has shown that the foregoing levels of vacuum and airflow work well with battery plates having a surface area up to about 56 square inches. While these levels of vacuum and airflow may work for larger plates, it is not known if they will.

While the foregoing vacuum is too low to hold the more porous plates on the pick-up head, combined with the larger air flow it will pick up even the most porous plates. This is because the large air flow causes the vacuum to act over the entire plate area and create a lifting force that is greater than the same level a vacuum would provide if it were only acting over the area of the opening in a pickup head, which occurs with the high vacuum, low flow pickup heads of the prior art. Once the plate is up against the pickup head, the vacuum only works against the portion of the plate covered by the pickup opening. However, when a vacuum inlet is closed the pressure decreases momentarily, and this increased vacuum is sufficient to hold the plate on the pickup head long enough for the plate to be transported to an outfeed mechanism 30.

In operation a low vacuum, high volume flow is provided at the pickup head 18 by the vacuum source 24. The pickup mechanism 28 lowers the pickup head to a point where the air flow acting over the entire face of the plate causes the top plate 12 a to be lifted off of the stack and into contact with the pickup head, FIG. 2. The pickup mechanism 28 then lifts the pickup head and translates it sideways toward the outfeed mechanism 30 to where the plate 12 a is inserted between the outfeed rollers 32. The outfeed rollers 32 pull the plate 12 a off of the pickup head and deposit it onto the outfeed conveyor 34 where it is transported away from the feeder for further processing.

Referring now to FIGS. 5-10, rather than using a single pickup head 18 and raising a single stack of plates 12 upwardly toward the pickup head every time a plate is removed from the stack, a plurality of pickup heads 36 a-36 e simultaneously remove plates from a like number of stacks 38 a-38 e. Each pickup head has a pickup face 40, FIG. 10, with a pickup opening 42 having an area relative to the area of the plate 44 that is the same as the opening 22 in the pickup head 18 is to the plate 12. The pickup heads are suspended from a pickup frame 46 in a manner such that their pickup faces are horizontal and lie in a common plane. The pickup heads 36 a-36 e are connected to a common vacuum source, shown schematically as 48, through a duct system 50, FIG. 9. A valve, shown schematically at 52, allows the vacuum source to be connected to or disconnected from the pickup heads, as will be more fully explained later.

The pickup heads have collapsible devices located in them downstream of the pickup openings. While the collapsible device illustrated in the drawings is a bellows 54, it could be a telescoping pipe section or other device. When a plate 44 is placed into contact with a pickup head, and thus closes the pickup opening, the vacuum at that pickup head will increase. This increased vacuum will cause the collapsible device to collapse and move the pickup face and plate upwardly. Thus the plate is pulled clear of the stack it was removed from automatically without the need for any mechanical lifting mechanism.

In order to eliminate the vertical stack indexing mechanism, the stacks of plates are fed on an infeed conveyor 56 which is oriented at an angle a with respect to the plane of the pickup faces 40. As a practical matter, a pickup head can sequentially pick up several plates from a stack, the exact number depending on the porosity and the weight of the plates. For the remainder of this discussion it will be assumed that a pickup head will sequentially pick up five plates from the same stack. However, for ease of illustration, FIG. 5 shows the angle a such that only one plate will be picked up from each stack. The pickup heads are separated from one another by a distance A, and this distance and the angle a are such that the nominal separation distance between the pickup faces 40 and the top of the infeed conveyor decreases from pickup head to pickup head by an amount equal to roughly the thickness of the number of plates that will be removed from each stack, in this case five plates. Thus if each stack has five less plates than the preceding stack, the distance between the pickup face of each pickup head and the top plate in its respective stack is roughly the same. The thickness of battery plates vary from plate to plate so different stacks with the same number of plates may have different heights. Thus, this distance could vary considerably from stack to stack. With this scenario, the stacks will contain 25 plates, although on start-up, the first stack will contain 5 plates, the second stack 10 plates, the third stack 15 plates, the fourth stack 20 plates and the fifth stack 25. After 5 plates have been removed from each stack the infeed conveyor is activated to move the stacks a distance equal to the pickup head separation distance A.

Referring now also to FIGS. 6-9, a transport mechanism 58 allows the frame 46 to be moved in a direction normal to the direction of the infeed conveyor 56. Thus, each time plates are picked up by the pickup heads the frame is moved from a pickup position over the infeed conveyor, shown in FIGS. 5, 6 and 8, to a deposit position over an outfeed conveyor 60, which is parallel with the infeed conveyor 56.

The embodiment of the transport mechanism 58 shown in the drawings includes a pair of guiderails 62, located outwardly of each end of the frame 46, which extend across the infeed conveyor 56 and the outfeed conveyor 60. A trolley 64 is attached movably to each guiderail 62 by means of pairs of upper and lower rollers 66. A platform 68, which is attached to each trolley 64, is attached to a mount 70 which in turn is attached to one end of the frame 46. This allows the frame 46 to be moved between its pickup position, over the infeed conveyor 56, and its deposit position, over the outfeed conveyor 60, by moving the trolleys 64 along the guiderails 62.

Each platform 68 is attached to its mount 70 through the piston 72 of a pneumatic cylinder 75. This allows the frame to be raised as the pickup heads are moved between their pickup and deposit positions to clear the structure which supports the infeed and outfeed conveyors. Spring dampers 73 or shock absorbers cushion the frame as it is being lowered. Movement of the trolleys back and forth along the guiderails is accomplished by means of an electric motor 74 which operates through an appropriate rotary-to-linear reciprocating linkage 76.

A microprocessor controller 78 is connected to the motor 74, the pneumatic cylinder 75, the vacuum valve 52 and limit switches 80 a and 80 b located at each end of one of the guiderails 62 to control the operation of the apparatus as follows. Assuming that five plates will be picked up by each pickup head 36 a-36 e from each stack 38 a-38 e, the process is started by placing on the infeed conveyor 25 plates in stack 38 a under pickup head 36 a, 20 plates in stack 38 b under pickup head 36 b, 15 plates in stack 38 c under pickup head 36 c, 10 plates in stack 38 d under pickup head 36 d and 5 plates in stack 38 e under pickup head 36 e. The controller then causes the valve 52 to open thereby providing vacuum to all 5 pickup heads. This causes the top plate 44 to be pulled off of each stack and into contact with the respective pickup face 40, FIG. 8. The controller then causes the motor 78 to move the trolleys 68 along the guiderails 62 to the deposit position, FIG. 9, where one of the trolleys engages the limit switch 80 a. The controller then stops the motor 74 and closes the valve 52, which causes the plates 44 to drop from the pickup heads onto the outfeed conveyor 60, where they are transported out of the apparatus. The controller then restarts the motor 78 and the trolleys 68 are moved back to the pickup position, where one of the trolleys engages the limit switch 80 b. This causes the controller to stop the motor and open the valve 52 to initiate vacuum flow again in the pickup heads. The second plate in each stack is then picked up and the process is repeated.

After the desired number of plates have been picked up, 5 in the example being discussed, the infeed conveyor 56 is activated to move the four remaining stacks downstream a distance equal to the pickup head separation distance A. Thus, stack 38 d, which now contains five plates, is placed under pickup head 36 e, stack 38 c, which now contains 10 plates, is placed under pickup head 36 d, stack 38 b, which now contains 15 plates, is placed under pickup head 36 c and stack 36 a, which now contains 20 plates, is placed under pickup head 36 b. Simultaneously the controller activates a supply conveyor 78 which places a new stack 38 f of 25 plates on the outfeed container so that this stack will be located under feed head 36 a. The entire process is then repeated.

When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 

1. A pickup mechanism for removing porous battery plates from a stack of battery plates, comprising: a pickup head for removing a top plate from the stack of battery plates, the pickup head having a pickup face with an opening having a predetermined opening area defined therein; and a vacuum source connected to said pickup head adapted to pull the top plate against the pick-up head such that a surface area of the plate contacts the pick-up head, said vacuum source and said predetermined opening being sized such that a vacuum of less than 7 inches of water and an air flow of more than 200 CFM is created at said opening.
 2. The pickup mechanism of claim 1 wherein said predetermined opening area is at least 50% of said surface area of the top plate.
 3. The pickup mechanism of claim 1 wherein the vacuum created at said opening is between 2 inches of water and 7 inches of water.
 4. The pickup mechanism of claim 1 wherein the air flow created at said opening is between 200 CFM and 800 CFM.
 5. The pickup mechanism of claim 1 in combination with a platform for supporting the stack of battery plates disposed below the pickup mechanism, and in combination with an oscillation mechanism which moves said pick-up head downwardly toward said top plate to a point where said vacuum will pull said top plate off of said stack and up against said pick-up face, and then moves said pickup head upwardly to where said top plate can be removed from said pickup head by an outfeed mechanism.
 6. The pickup mechanism of claim 5 in further combination with a lifting mechanism that raises said platform an incremental amount each time a plate is removed from said stack.
 7. A pickup mechanism for removing porous battery plates from a stack of battery plates, comprising: a pickup head for removing a top plate from the stack of battery plates, the pickup head having a pickup face with an opening having a predetermined opening area defined therein; and a vacuum source connected to said pickup head adapted to pull the top plate up against the pick-up head such that a surface area of the plate contacts the pick-up head, said predetermined opening area being at least 50% of said surface area of the top plate.
 8. The pickup mechanism of claim 7 wherein said vacuum source and said predetermined opening is sized such that a vacuum of less than 7 inches of water and an air flow of more than 200 CFM is created at said opening.
 9. The pickup mechanism of claim 8 wherein the vacuum created at said opening is between 2 inches of water and 7 inches of water.
 10. The pickup mechanism of claim 8 wherein the air flow created at said opening is between 200 CFM and 800 CFM.
 11. The pickup mechanism of claim 7 in combination with a platform for supporting the stack of battery plates disposed below the pickup mechanism, and in combination with an oscillation mechanism which moves said pick-up head downwardly toward said top plate to a point where a vacuum at the predetermined opening will pull said top plate off of said stack and up against said pick-up face, and then moves said pickup head upwardly to where said top plate can be removed from said pickup head by an outfeed mechanism.
 12. The pickup mechanism of claim 11 in further combination with a lifting mechanism that raises said platform an incremental amount each time a plate is removed from said stack.
 13. A method for removing a porous battery plate from a stack of battery plates comprising: providing a stack of battery plates; providing a pickup head having a pickup face with an opening having a predetermined opening area; creating a vacuum of less than 7 inches of water and an airflow of more than 200 CFM at said opening; and moving said pickup head toward said stack of battery plates to where a top plate in said stack is pulled away from said stack and up against its pick-up face.
 14. The method of claim 13 wherein said vacuum is between 2 inches of water and 7 inches of water.
 15. The method of claim 13 wherein said air flow is between 200 CFM and 800 CFM.
 16. The method of claim 13 wherein said vacuum may be insufficient to hold said plate on said pickup head indefinitely against the force of gravity.
 17. The method of claim 13 wherein the predetermined opening area is at least 50% of said surface area of the top plate. 